Had a go at setting up my gears today, and this was the best so far.

D30 HP
Used 4.10 gears
New bearings 25" lb pinion preload
.007" backlash

 

Pinion is way to deep.

The tell-tale sign is the straight line across the bottom of the pattern.

What's the backlash now?

 

agreed ,your looking for little half moon shapes

 

Helping my buddy do the seals (front axle w disconnect) in his yj 4 banger. Do we have to pull the gear set out and do a pattern to do this operation? I'm a suzuki guy so am ignorant about non 3rd member gears

 

No.
Just pull the carrier and reinstall.

 

Cool, was hoping to just keep the shims in order so as to avoid the pattern process. Am a lazy suzuki guy afterall, did I mention that. I am not too proud to run with jeeps tho, no pictures tho please

 

The shims are under the bearings, you'll never see 'em unless you pull the bearings off the carrier.

 

So back to messing with it today. Brought the pinion out a bit, don't wanna misinterprit this one. Back lash is .006. Looking at the coast side with the straight edge across the top I see this as pinion being too far? When I bring it in .003 the coast side pattern moves significantly to the toe. I've read an artical that says to pay little attention to position on heel and toe but to be more focus to the flank and face. This is a used gearset so I also heard I should be looking at the coast side pattern more. Thanks for input so far.

 

Gave it a couple more shots and am having a harding time getting the contact off the face of the coast side without getting a flat line on the drive side.

 

Wrap a shop towel around the round part of the yoke and apply a lot of resistance. This will give you a much better pattern on the ring gear.